Base interlining, methods for their manufacture and application thereof

ABSTRACT

The invention relates to a novel binder system and its use for bonding textile fabrics as well as products containing such bonded textile fabrics. The materials according to the invention are suitable for manufacturing base interlinings which may be used for manufacturing base interlinings for sarking, roofing and sealing membranes, particularly for manufacturing coated sarking, roofing and sealing membranes.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of pending U.S. application Ser. No.15/404,790, filed Jan. 12, 2017, which is a division of U.S. applicationSer. No. 12/746,228, filed Mar. 30, 2011, now U.S. Pat. No. 9,574,291issued Feb. 21, 2017, which is a 371 of PCT/US2008/085845, filed Dec. 8,2008, which claims priority to German Application No. 10 2007 060 494.9,filed Dec. 14, 2007.

The invention relates to a novel binder system and its use in textilefabrics as well as to 5 products containing the binder system or atextile fabric equipped therewith.

Textile fabrics, particularly base interlinings for the manufacture ofroofing membranes have to meet a variety of requirements. In particular,base interlinings are to have a sufficient mechanical stability, such asgood perforation strength and good tensile 10 strength occurring, forexample, in processing such as bituminizing or laying.

Furthermore, a high heat stability, for example, during bituminizing orstability against radiating heat and resistance to spreading fire arerequired. Thus, there have been lots of trials to improve the presentbase interlinings as regards these requirements.

One way of improvement is to combine non-woven fabrics based onsynthetic nonwovens with reinforcement fibers, such as glass fibers, inorder to improve their mechanical stability. Examples for such sealingmembranes can be found in the documents GB-A-1,517,595,DE-Gbm-77-39,489, JP-A-81-5879, EP-A-160,609, EP-A-176-847, EP-A-403,403and EP-A-530,769. The non-woven fabric and the reinforcing fibers arebonded according to this state of the art either by conglutinating witha binding agent or by needle-punching the layers made of differentmaterials.

Another way for improvement is to manufacture composite materials byknitting or stitch bonding (DE-A-3,347,280, U.S. Pat. No. 4,472,086,EP-A-333,602 and EP-A-395,548) or to realize a combination ofreinforcing fibers in the form of bi-component fibers with non-wovenfabrics based on synthetic fibers (U.S. Pat. No. 4,504,539 andEP-A-0,281,643).

The technical textile fabrics known from the state of the art show goodapplication-specific properties, however, the permanent task remains tostill improve even these products, with no increasing manufacturingcosts, if possible.

Thus, the task of the present invention was to provide improved textilefabrics being particularly suitable as base interlining for coatedsarking, roofing and sealing membranes and which may be manufactured incommercial amounts at a reasonable price. A further task of theinvention is to make sure that the textile fabrics may be provided witha coating by known and established methods.

Surprisingly, it has now been found that textile fabrics beingsolidified by means of a special binder system have improved heatdimensional stability and that in spite of water absorption the ageingcharacteristics, the flexibility or stabilities have not significantlydeclined.

Thus, the object of the present invention is a textile fabric beingsolidified with a binder system, comprising:

-   a) 10 to 90 wt % of an aqueous dispersion of polymerisates based on    conjugated aliphatic dienes and vinyl aromatic compounds-   b) 90 to 10 wt % starch,-   c) 0 to 10 wt % additives,

with the figures for the percentage by weight relating to the dry massof the binder system, i.e. without water.

Another object of the present invention is the binder system usedaccording to the invention.

Surprisingly, the textile fabric manufactured by means of the bindersystem according to the invention has a higher heat dimensionalstability compared to the textile fabrics which have only been bondedwith component a). Also surprisingly, the stabilities and the ageingcharacteristics remain steady, although a person skilled in the artwould expect deterioration.

The textile fabric solidified according to the invention is improved asregards stability, ageing characteristics and flexibility compared tothe textile fabric having only component b) as a binder.

By partly using starch as a replacement, significant cost savings may berealized. Additionally, a completely formaldehyde-free binder system isobtained without having to accept cutbacks in product properties.Surprisingly, product properties are even improved.

The aqueous dispersion of polymerisates based on conjugated aliphaticdienes and vinyl aromatic compounds used according to the invention areknown as such. Suitable dispersions and manufacturing methods aredescribed, for example, in DE-A-2602445, DE-A-2602444 and U.S. Pat. No.3,575,913.

Normally, known emulgators or protective colloids may be added tostabilize the aqueous polymer dispersions. These are known to the personskilled in the art (cf. Houben-Weyl, Methoden der org. Chemie, vol.XIV/1, 1961, Stuttgart). Examples for emulgators are polyalkyleneglycol, sulfonated parafinic hydrocarbons, higher alkyl sulphates (e.g.lauryl sulphate), alkaline metallic salt of fatty acids, such as sodiumstearate or sodium oleate, sulfuric acid semi-ester of ethoxylated fattyacid alcohols, salts of esters and semi-esters of alkylpolyoxyethylenesulphosuccinates, salts of sulphonated alkyl aromates, such as sodiumdodecylbenzenesulphonate, ethoxylated C4-C12-alylphenoles and theirsulphonation products, as well as esters of sulphosuccinic acid.Examples for protective colloids are alkylhydroxyalkylcelluloses, partlyor completely hydrolysed polyvinylalcohols and copolymers thereof,acrylic acid, homopolymers and copolymers and partly neutralized saltsthereof, acrylamide copolymers, polyacrylate copolymers and saltsthereof, carboxyalkylcellulose, such as carboxymethylcellulose and itssalts.

Furthermore, the polymer dispersions may have carboxyl groups insertedin the polymers for stabilization.

The aqueous dispersions used according to the invention are normallymanufactured by emulsion polymerization of:

-   a) 20 to 80 parts by weight of conjugated aliphatic dienes,-   b) 20 to 80 parts by weight of vinyl aromatic compounds,-   c) 0 to 10 parts by weight of ethylenic unsaturated carboxylic acids    and/or dicarboxylic acids,-   d) 0 to 20 parts by weight of ethylenic unsaturated carboxylic acid    nitriles in the presence of water, emulgators and water soluble    initiators.

The content of emulgators usually amounts to 1 to 5 parts by weight (inrelation to 100 parts by weight of the components a) to d)).

Preferred dispersions may be obtained by emulsion polymerization of 25to 65 parts by weight of component a), 25 to 65 parts by weight ofcomponent b), 0.1 to 6 parts by weight of component c) and/or 0.1 to 15parts by weight of component d).

Particularly preferred dispersions contain maximally 5 parts by weightof ethylenic unsaturated carboxylic acids and/or dicarboxylic acids,particularly maximally 3 parts by weight of ethylenic unsaturatedcarboxylic acids and/or dicarboxylic acids, very particularly preferredno ethylenic unsaturated carboxylic acids and/or dicarboxylic acids,comprising the acids mentioned above as well as derivatives thereof.

Particularly preferred dispersions contain maximally 5 parts by weightof ethylenic unsaturated carboxylic acid nitriles, particularlymaximally 3 parts by weight of ethylenic unsaturated carboxylic acidnitriles, very particularly preferred no ethylenic unsaturatedcarboxylic acid nitriles.

Butadiene, isoprene, pentadiene-1,3, dimethylbutadiene and/orcyclopentadiene are preferably considered as conjugated aliphatic dienes(component a)).

Styrene, a-methylstyrene and/or vinyltoluene are particularly mentionedas vinylaromatic compounds (component b)).

α, β-monoethylenic unsaturated mono- and dicarboxylic acids with 3 to 6C-atoms such as acrylic acid, methacrylic acid, maleic acid, fumaricacid and itaconic acid are preferably used as ethylenic unsaturatedcarboxylic acids and/or dicarboxylic acids (component c)).

Acryl nitrile and/or methacryl nitrile are particularly mentioned asethylenic unsaturated carboxylic acid nitriles.

Systems normally used in emulsion polymerization are added asinitiators. These water soluble systems, such as peroxides and azocompounds, are known to the person skilled in the art. Usually, thewater soluble initiators are added in an amount of 0.1 to 2.0 wt % inrelation to the total mass of the monomers to be polymerized.

Moreover, the known molecular weight regulators and other auxiliaryagents, e.g. complexing agents for disturbing metal ions, or inhibitors,e.g. hydrochinon monomethylether, may be added for the emulsionpolymerization (cf. Houben-Weyl, Methoden der organischen Chemie, vol.XIV/1, pp. 297 ff., 1961, Stuttgart; Hans-Georg 5 Elias; Makromoleküle;1990; Hüttig&Wepf Verlag, Basel, Heidelberg, N.Y.).

Insofar as unsaturated carboxylic acids and/or dicarboxylic acids(component c) are used for polymerization, neutralization with baseswill be required.

The solids content of the dispersions used according to the inventionamounts to between 30 and 70 wt %, preferably between 35 and 68 wt %,particularly preferred between 40 and 67 wt % (determined in accordancewith DIN EN ISO 3251).

The viscosity of the dispersions used according to the invention amountsto between 10 and 2200 mPa*s, particularly between 10 and 500 mPa*s,particularly preferred between 15 and 300 mPa*s (determined inaccordance with DIN EN ISO 3219 and 23° C.).

The polymer dispersions used according to the invention are preferablyanionic 20 dispersions. Further, bathotonic and/or thermallycross-linkable dispersions are preferred. Those thermal cross-linkabledispersions that cross-link at a temperature range between 120° C. and200° C. are preferred. The bathotonic dispersions may already be partlycross-linked, particularly if parts of the water had been removed fromthe aqueous dispersion.

The dispersions used according to the invention are marketed under thedesignations such as Synthomer (Synthomer Ltd.), Lutofan® or Styrofan®(BASF AG), SRG Types (Dow Chemicals) and Plextol SBV Types(PolymerLatex).

The starches used according to the invention are not subject to anylimitation, however, they have to be compatible with the aqueous polymerdispersion and also with the binder liquor. Suitable starches arenatural—so-called—native starches and modified starches, such ascationic or anionic starches or starch derivatives (so-called chemicallymodified starches). Generally advantageous are starches having asufficient solubility in cold and/or hot medium.

A group of starches that might be used in the context of the inventioncomprises starches extracted from vegetable raw materials. These includeamong others starches from tubers, such as potatoes, manioc, arrowroot,batata, from seeds, such as wheat, maize, rye, rice, barley, millet,oat, sorghum, from fruits, such as chestnuts, acorns, beans, peas, andother pulses, bananas, as well as from plant marrow, e.g. of the sagopalm.

The starches which can be used in the context of the inventionessentially consist of amylose and amylopectin in changing quantitiveratios.

The molecular weights of the starches useful according to the inventionmay vary in a wide range. The starches consisting essentially of amixture of amylose and amylopectin, preferably have a molecular weightM_(w) of between 5×10² and 1×10⁸, particularly preferably between 5×10⁴and 1×10⁷.

In addition to starches of native vegetable origin also starches areequally preferred which were chemically modified, enzymaticallyextracted, are of recombinant origin or were manufactured bybiotransformation (biocatalysis).

The term “biocatalysis” is also used as a synonym for the term“biotransformation”.

“Chemically modified starches” are defined as starches whose propertieswere chemically modified compared to the natural properties. This isessentially obtained by polymer analogue conversions, where starch istreated with mono-, bi- or polyfunctional reagents or oxidants. In thisprocess, preferably the hydroxyl groups of the starch are modified byetherification, esterification or selective oxidation; or themodification is based on a radically initiated graft copolymerization ofcopolymerizable unsaturated monomers on the starch backbone.

To special chemically modified starches belong among others starchesters, such as xanthogenates, acetates, phosphates, sulfates, nitrates,starch ethers, such as non-ionic, anionic or cationic starch ethers,oxidized starches, such as dialdehyde starch, carboxy starch, starchesdegraded by persulfate and similar substances.

In the linguistic usage of the invention, “fermentative starches” refersto starches which are extracted in fermentative processes using naturalorganisms, such as fungi, algae or bacteria, or which may be extractedwith the activation and help of fermentative processes. Examples forstarches obtained from fermentative processes include among others gumarabicum and related polysaccharides (gellan gum, gum ghatti, gumkaraya, gum tragacauth), xanthan, emulsan, rhamsan, wellan,schizophyllan, polygalacturonates, laminarin, amylose, amylopectin andpectines.

Starches of recombinant origin or “recombinant starches” in theinvention refers to starches which are extracted in fermentativeprocesses using unnatural organisms, but with the help of naturalorganisms that are modified by using genetic methods, such as fungi,algae or bacteria, or which may be extracted with the activation andhelp of fermentative processes. Examples for starches obtained fromfermentative, genetically modified processes include among othersamylose, amylopectin and polyglucanes.

In the context of the invention, “starches manufactured bybiotransformation” means that starches, amylose, amylopectin orpolyglucanes are manufactured by catalytic reaction of monomeric basicmodules, i.e. generally oligomer saccharides, particularly mono- anddisaccharides, using a biocatalyst (also: enzyme) under specialconditions. Examples for starches obtained from biocatalytic processesare among others polyglucan and modified polyglucanes, polyfructan andmodified polyfructanes.

Further, the invention also comprises derivatives of the individualstarches mentioned. In this process, the terms “derivative of starches”or “starch derivatives” generally refer to modified starches, i.e. suchstarches in which the natural amylose/amylopectin ratio was modified, apre-gelatinization was carried out, which were subject to a hydrolyticdegradation or chemically derivatized.

To particular derivatives of starches belong among others oxidizedstarches, e.g. dialdehyde starch or other oxidization products withcarboxyl functions, or native ionic starches (for example with phosphategroups) or ionically further modified starches, meaning both anionic andcationic modifications.

To the destructurized starches, which may be used in the context of theinvention, belong those, which for example were homogenized by means ofglycerine such that no more crystalline reflexes occur in the X-raydiffraction and starch grains or double refracting regions are no longervisible at a thousand-fold magnification in the polarization microscope.In this context, reference is made to document DE-A1-3931363, whosedisclosure of destructurized starches is also part of the presentdescription.

The starches used according to the invention are marketed e.g. by Avebe,Cargill, National Starch, Penford Products Co Purac or Südstärke.

Especially advantageous are starches which have a sufficient solubilityin cold and/or hot medium. A sufficient solubility is given if theviscosity of the binder system according to the invention allows arespective workability.

The binder system used according to the invention may also contain up to10 wt % additives. This includes commercial additives such aspreservatives, stabilizers, anti-oxidants, antifoaming agents,waterproofing agents, UV stabilizers, fillers and/or pigments. They arepartly contained in the commercial products and serve to stabilizestorage and transport or may be added later in order to meet thecustomer's specifications.

The quantity of the binder system according to the invention applied tothe textile fabric preferably amounts to between 5 and 35 wt % of drybinder after drying, particularly 10 and 30 wt %, particularly preferred10 and 25 wt % dry binder in relation to the total weight of the rawtextile fabric.

The term “textile fabric” in the context of the present description isto be understood in its widest meaning. It may refer to all fiberfabrics being manufactured according to a fabric-forming technology. Thefiber-forming materials include natural fibers and/or fibers made ofsynthesized polymers. Examples for such textile fabrics are wovenfabrics, scrims, knitted fabrics as well as preferably non-wovenfabrics.

Spunbonded non-wovens, so-called spunbonds manufactured by randomdeposition of freshly melt-spun filaments are preferred of thenon-wovens made of synthetic polymer fibers. They consist of endlesssynthetic fibers made of melt-spunnable polymer materials. Suitablepolymer materials are for example polyamids, such as polyhexamethylendiadipamide, polycaprolactam, aromatic or partially aromatic polyamides(“aramides”), aliphatic polyamides, such as nylon, partially aromatic orfully aromatic polyesters, polyphenylene sulphide (PPS), polymers withether and keto groups, such as polyether ketones (PEK) and polyetheretherketone (PEEK) polyolefins, such as polyethylene or polypropylene,or polybenzimidazoles.

Preferably, the spunbonded non-wovens consist of melt-spinnablepolyesters. In principle, all types of polyester material suited for theproduction of fibers may be considered. Such polyesters for the mostpart consist of constituents derived from aromatic dicarboxylic acidsand aliphatic diols. Common aromatic dicarboxylic acid constituents arethe bivalent residues of benzene dicarboxylic acids, especiallyterephthalic acid and isophthalic acid; common diols have two to four Catoms, ethylene glycol being particularly suitable. Spunbondednon-wovens which consist of at least 85 mol % polyethylene terephthalateare particularly advantageous. The remaining 15 mol % are then made upof dicarboxylic acid units and glycol units, which act as so-calledmodification agents and which will enable the person skilled in the artto purposely influence the physical and chemical characteristics of themanufactured filaments. Examples of such dicarboxylic acid units areresidues of isophthalic acid or of aliphatic dicarboxylic acid, such asglutaric acid, adipic acid, and sebacic acid; examples of modifying diolresidues are those composed of longer-chain diols, such as propane diolor butane diol, of di or triethylene glycol or, if present in smallquantities, of polyglycol with a molar weight of approximately 500 to2000.

Polyesters containing at least 95 mol % of polyethylene terephthalate(PET) are particularly preferred, especially those composed ofunmodified PET.

If the base interlinings shall additionally have a flame retardanteffect, it is advantageous if they were spun of flame retardantlymodified polyesters. Such flame retardantly modified polyesters areknown. They contain additives of halogene compounds, particularlybromine compounds or, which is particularly advantageous, they containphosphonic compounds that are condensed into the polyester chain.

Particularly preferably, the spunbonded non-wovens contain flameretardantly modified polyesters containing modules in the chain with theformula (I)

wherein R is alkaline or polyethylene with 2 to 6 C atoms or phenyl andR¹ is alkyl with 1 to 6 C atoms, aryl or an alkyl, are condensed into.Preferably, in the formula (I) R means ethylene and R¹ methyl, ethyl,phenyl or o-, m- or p-methylphenyl, particularly methyl. Such spunbondednon-wovens are, for example, described in DE-A-39 40 713.

The polyesters contained in the spunbonded non-wovens preferably have amolecular weight corresponding to an intrinsic viscosity (IV) of 0.6 to1.4, measured in a solution of 1 g polymer in 100 ml dichloroacetic acidat 25° C.

The individual titers of the polyester filaments in the spunbondednon-woven amount to between 1 and 16 dtex, preferably between 2 and 8dtex.

In a further embodiment of the invention, the textile fabric of thespunbonded non-woven may also be a fusible binder-bonded non-wovenfabric, which contains base and hot melt adhesive fibers. The base andhot melt adhesive fibers may be derived from any thermoplasticfilament-forming polymers. Base fibers may also be derived fromnon-melting filament-forming polymers. Such hot melt binder spunbondednon-wovens are described, for example, in EP-A 0,446,822 and EP-A0,590,629.

Examples of polymers from which the base fibers may be derived arepolyacrylonitrile, polyolefins, such as polyethylene or polypropylene,essentially aliphatic polyamides, such as nylon 6.6, essentiallyaromatic polyamides (aramides), such as poly-(p-phenylene terephthalate)or copolymers containing a proportion of aromatic m-diamine units toimprove the solubility or poly-(m-phenylene isophthalate), essentiallyaromatic polyesters, such as poly-(p-hydroxy benzoate) or preferablyessentially aliphatic polyesters, such as polyethylene terephthalate.

The relative proportion of the two fiber types may be selected withinwide limits, whilst making sure that the proportion of the hot meltadhesive fibers is sufficient to bond the base fibers to the hot meltadhesive fibers, thereby endowing the non-woven fabric with a strengthsufficient for the intend application. The proportion of the hot meltadhesive in the non-woven fabric originating from the hot melt adhesivefiber is usually less than 50 wt % (in relation to the weight of thenon-woven fabric).

Modified polyesters having a melting point 10 to 50° C., preferably 30to 50° C., lower than the raw material of the non-woven fabric areparticularly considered as hot melt adhesive. Examples of such a hotmelt adhesive are polypropylene, polybutylene terephthalate, orpolyethylene terephthalate modified by the condensation of longer-chaindiols and/or isophthalic acid or aliphatic dicarboxylic acid.

The hot melt adhesives are preferably incorporated into the non-wovensin fibrous form.

The base and hot melt adhesive fibers are preferably made up of oneclass of polymers. This means that all of the fibers used are selectedfrom one class of substances, so that these may readily be recycledafter the non-woven has been used. If the base fibers consist ofpolyester, for example, the hot melt adhesive fibers selected willlikewise be of polyester or a mixture of polyesters, for example in theform of bi-component fibers with PET in the core and a polyethyleneterephthalate copolymer having a low melting point as outer coat. Inaddition, however, bi-component fibers which are made up of differentpolymers are also possible. Examples of these are bi-component fibers ofpolyester and polyamide (core/outer coat).

The monofilament titre of the base and the hot melt adhesive fibers maybe selected within wide limits. Examples of common titre ranges are 1 to16 dtex, preferably 2 to 6 dtex.

Insofar as the base interlinings according to the invention withflame-retardant properties are additionally bonded, they preferablycontain flame-retardant hot melt adhesives. A polyethylene terephthalatemodified by inserting chain members of the formula (I) mentioned abovemay be present as flame-retardant hot melt adhesive in the layer fabricaccording to the invention.

In a preferred embodiment of the invention the textile fabric wassubjected to mechanical and chemical bonding with the binder systemaccording to the invention. Such a bonding further improves theapplication properties of the base interlining.

The bonding may be carried out in single steps or altogether whilstmaking sure that particularly in the presence of reinforcements anoptionally present reinforcement is not or only very little damaged. Thebonding is carried out by means of known methods. Without limiting thepossible methods, mechanical methods, such as needle-punching,particularly hydrodynamic bonding as well as chemical and/orthermoplastic methods are suitable.

Insofar as the bonding is carried out by needle-punching, it is donewith stitch densities of 20 to 100 pricks/cm², preferably with 40pricks/cm². A hydrodynamic bonding may also be carried out instead of oradditionally to mechanical needle-punching. Preferably, this process iswaterjet needling. The pressure during waterjet needling is preferablybetween 5 and 600 bar, particularly between 50 and 450 bar, particularlypreferred between 100 and 300 bar.

The nozzle diameter is between 0.05 and 0.25 mm, preferably between 0.07and 0.2 mm. The nozzles are arranged in the form of so-called beams. Thenumber of nozzles is between 10 and 60 nozzles per inch, preferablybetween 20 and 40 per inch.

Likewise other fluid media may be used instead of water and the waterjetneedling may be carried out in several separate steps. The waterjetneedling may be carried out with a continuous jet or as well by means ofa pulsed waterjet, the pulse frequency not being limited. Waterjetneedling is preferred particularly in the presence of reinforcements.

The filaments or staple fibers making up the non-woven fabrics may havea virtually circular cross section or may also have other shapes, suchas dumb bell-shaped, reniform, triangular, trilobal or multilobal crosssections. Hollow fibers and bi-component or multi-component fibers mayalso be used. Further, the hot-melt adhesive fibers may also be used inthe form of bi-component or multi-component fibers.

The textile fabric may be a single- or multilayered fabric.

The fibers forming the textile fabric may also be modified by means ofthe usual additives, for example by antistatic agents such as carbonblack, or flame-retardant additives, such as fire protecting agents.Preferably, these additives are added to the binder system according tothe invention.

The weight per unit area of the textile fabric, particularly of thespunbonded non-woven is between 20 and 500 g/m², preferably 40 and 400g/m², particularly between 90 and 250 gg/m².

To the complete surprise of persons skilled in the art, the use of thebinder system according to the invention improves the heat dimensionalstability of the textile fabric. Thus, an improvement of the dimensionalstability in longitudinal direction of at least 15% is detected (inrelation to a textile fabric with binders based on styrol/butadien “SBR”dispersion binders), preferably of at least 20% and in cross directionan improvement of the dimensional stability of at least 15% is detected(in relation to a textile fabric with binders based on styrol/butadien“SBR” dispersion binders), preferably of at least 20%.

In a preferred embodiment of the invention the heat dimensionalstability of the textile fabric bonded with the binder system accordingto the invention is maximally 1.6% in longitudinal direction andmaximally 1.7% in cross direction, particularly maximally 1.5% inlongitudinal direction and 1.5% in cross direction.

The heat dimensional stability is measured as follows: The samples arestamped out in the dimension 350 mm×100 mm (l/c) and measured.Afterwards the samples are loaded with a weight of 4 kg in longitudinaldirection across their overall width and vertically hung into a dryingoven for 10 minutes at a temperature of 200° C. The measurement of thedimensional variation is carried out after a 5 minutes cooldown whileleaving the weight of 4 kg. The result in % represents the variationcompared to the original value.

The textile fabrics according to the invention may be used as baseinterlining for coated sarking, roofing and sealing membranes, whichalso are object of the present invention.

In a further embodiment of the invention such base interlinings have atleast on reinforcement. They are preferably designed such that thereinforcement absorbs a force so that the reference force of the baseinterlining with reinforcement in the stress-elongation diagram (at 20°C.) compared to the base interlining without reinforcement differs inthe elongation range between 0 and 1% at at least one location by atleast 10%.

In a further embodiment the reinforcement may be inserted such that aforce may only be absorbed at higher elongations.

The good mechanical properties of the base interlining are obtainedparticularly with reinforcing filaments and/or yarns whose Young moduleis at least 5 GPa, preferably at least 10 GPa, particularly preferred 20GPa. The reinforcing filaments mentioned above, i.e. the monofilamentsas well as the yarns have a diameter between 0.1 and 1 mm or 10-400 tex,preferably 0.1 and 0.5 mm, particularly 0.1 and 0.3 mm and have anelongation at rupture of 0.5 to 100%, preferably 1 to 60%. Particularlyadvantageously, the base interlings according to the invention have anelongation reserve of less than 1%.

The elongation reserve denotes the elongation acting on the baseinterlining before the acting force is diverted to the reinforcingfilaments, i.e. an elongation reserve of 0% would mean that the tensileforces acting on the base interlining would immediately be diverted tothe reinforcing filaments. That implies that the forces acting on thetextile fabric do not lead to an alignment or orientation of thereinforcing filaments but are directly diverted to the reinforcingfilaments such that damage to the textile fabric may be avoided. This isparticularly demonstrated by a sharp increase of the force necessary forlittle elongations (stress-elongation diagram at room temperature).Additionally, the highest possible tensile force may be improved withthe help of suitable reinforcing filaments having a high elongation atrupture. Mono- or multifilaments made of polyester, for example, aresuitable reinforcing filaments.

As reinforcing filaments multi- and/or monofilaments are preferred basedon aramids, preferably so-called high-module aramids, carbon, glass,glass rovings, mineral fibers (basalt), high-strength polyestermonofilaments or multifilaments, high-strength polyamide monofilamentsor multifilaments, as well as hybrid multifilament yarns (yarnscontaining reinforcing filaments and lower melting binder fibers) orwires (monofilaments) made of metals or metallic alloys.

For economic reasons preferred reinforcements consist of glassmultifilaments in the form of—essentially—parallel warps or scrims. Inmost cases the non-wovens are reinforced in longitudinal directionby—essentially—parallel warps.

The reinforcing filaments may be used as woven fabric, scrim, knittedfabrics or as non-woven fabric by themselves or in the form of anindividual textile fabric. Reinforcements with parallel reinforcingfilaments, i.e. warps, as well as scrims or woven fabrics are preferred.

Depending on the wanted property profile, the density may vary in widelimits. Preferably the density is between 20 and 200 filaments permeter. The density is measured vertically to the running direction.Preferably, the reinforcing filaments are added during the formation ofthe spunbonded non-woven and thus embedded into the spunbondednon-woven. Also preferred is laying a non-woven on the reinforcement orthe later formation of a layer of reinforcement and the non-woven fabricby assembling.

Preferred base interlinings according to the invention have at least onereinforcement and show in the stress-elongation diagram (at 20° C.) thatthe reference force of the base interlining with reinforcement comparedto the base interlining without reinforcement differs in the elongationrange between 0 and 1% at at least one location by at least 10%,preferably by at least 20° %, particularly preferred by at least 30%.

For a whole range of applications a high module with low elongationsalso at room temperature is wanted. This high module improves the easeof handling, especially of light non-woven fabrics.

Depending on the requirement profile and also on cost aspects, thereference force of the reinforced base interlining may be distributed atlow elongations in different proportions on the textile fabric or thereinforcements.

The reference force is measured according to the standard EN 29073, part3, on samples having a width of 5 cm at a free clamping length of 200mm. The numerical value of the pretension which is given in Centinewtoncorresponds to the numerical value of the grammage of the sample, whichis given in grammes per square meter.

The base interlining may be reinforced by inserting the reinforcementsin the textile fabric, at at least one face of the textile fabric or atany location of the base interlining, particularly in other textilefabrics varying from the first textile fabric or as an individualtextile fabric.

The base interlining according to the invention may have further textilefabrics in addition to the one already described. Preferably thesefurther textile fabrics differ from the textile fabric first mentioned,i.e. they are made of a different material.

Insofar as the textile fabric is formed of synthetic polymers, it may benecessary to insert further textile fabrics in the base interliningaccording to the invention to optimize the application-specificproperties.

These additional textile fabrics are preferably non-wovens based onmineral fibers and/or glass fibers.

The mineral fiber non-wovens used in the base interlining according tothe invention may be solidified by binders or by mechanical measures,such as needle-punching or hydrodynamic needle-punching. Particularlypreferred are carded webs from filaments, i.e. endlessly long fibers, orfrom staple fibers. The average diameter of the mineral fibers isbetween 8 and 15 μm, preferably between 10 and 12 μm.

Suitable mineral fibers comprise alumosilicate, ceramic, dolomiticfibers or fibers from vulcanites such as basalt, diabase, melaphyre.Those together are denoted as paleobasalts, whereas diabase is readilyreferred to as greenstone.

The weight per unit area of the mineral fiber non-wovens used accordingto the invention is between 25 and 200 g/m², preferably between 30 and70 g/m². The information given above are also valid for the glass-fibermats which will be described in the following.

The glass-fiber mats used in the base interlining according to theinvention may be bonded by binders or by mechanical measures, such asneedle-punching or hydrodynamic needle-punching. The glass fibers may befilaments or finite or cut glass fibers, the length of the latter fibersbeing between 1 and 40 mm, preferably 4 to 20 mm.

The average diameter of the glass fibers is between 6 and 20 μm,preferably between 8 and 15 μm.

Suitable glass fibers comprise glass types such as E-glass, S-glass,R-glass or C-glass, E-glass or C-glass being preferred for economicreasons.

The base interlinings according to the invention may be equipped withfurther functional layers in addition to the additional textile fibersof the glass and/or mineral fibers mentioned above. Hereunder are to beunderstood measures or functional layers increasing the root strength ofthe base interlining. These are also object of the invention.

The base interlinings according to the invention may be used formanufacturing coated sarking, roofing and sealing membranes, preferablyfor manufacturing bituminized sarking, roofing and sealing membranes.Apart from that, the bases according to the invention may be used inflooring applications and in the field of filtration.

In addition to bitumen, other materials such as polyethylene orpolyvinylchloride, polyurethanes, EPDM or TPO (polyolefines) may also beused as coating substances for the coated sarking, roofing and sealingmembranes.

The bituminized membranes contain at least one base membrane—asdescribed above—embedded in a bitumen matrix, the bitumen parts byweight of the weight per unit area of the bituminized roofing membranebeing preferably 60 to 97 wt % and of the spunbonded non-woven is 3 to40 wt %.

Optionally, the coated sarking, roofing and sealing membranes mayafterwards be powdered with a granular material, such as sand. Thecoated sarking, roofing and sealing membranes thus manufactureddistinguish themselves by good workability, particularly bituminizedsarking, roofing and sealing membranes.

Manufacturing the textile fabric according to the invention comprisesthe following measures:

-   a) Formation of a textile fabric and mechanical bonding thereof,-   b) Application of a binder system comprising:    -   I) 10 to 90 wt % of an aqueous dispersion of polymerisates based        on conjugated aliphatic dienes and vinyl aromatic compounds    -   II) 90 to 10 wt % starch,    -   III) 0 to 10 wt % additives,-   c) Drying and solidification of the binder

with the figures for the percentage by weight relating to the dry massof the binder system, i.e. without water.

The textile fabric is formed by means of known measures. Preferably theformation of the textile fabric described in a) is carried out throughforming a spunbonded non-woven by means of known spinning apparatuses.

For this, the melted polymer is loaded with polymers through a pluralityof spinneret rows behind one another or groups of spinneret rows. If amelt binder bonded spunbonded non-woven is to be manufactured, it isalternatingly loaded with polymers forming the base fiber and hot meltadhesive fibers. The spun polymer streams are stretched in a knownmanner, and are laid on a conveyor belt, e.g., by using a rotatingbaffle plate in dispersion texture or by forming a curtain.

The mechanical bonding is also carried out by means of known methods.

The insertion of the optionally present reinforcement is carried outduring or after forming the textile fabric or before or during theapplication of the binder system according to the invention. Thereinforcement and optionally any further heat treatment in themanufacturing process are preferably added under stress, in particularlongitudinal stress.

Further textile fabrics to be optionally inserted are added before orduring the solidification of the binder system according to theinvention.

The binder system from step b) is also applied by means of knownmethods. The binder application is preferably between 5 and 50 wt %(dry), particularly 10 and 30 wt %, particularly preferred 10 and 25 wt%, each in relation to the total weight of the textile fabric.

The binder is also dried or solidified by methods known to the personskilled in the art.

The individual methods are known as such, but are patentable in thecombination or order according to the invention.

EXAMPLES

The following table 1 shows a comparison of the textile fabrics bondedwith the binder system according to the invention against the respectivesingle components of the binders.

A spunbonded non-woven based on polyethylene terephthalate(PET-spunbond) with a weight per area unit of 180 g/m² (Type JM33/180)is examined.

Example 1 shows a standard binder system based on SBR and urea binder,example 2 shows a binder system based on urea and acrylate, example 3shows a binder system according to the invention, example 4 shows abinder system based on starch and acrylate, example 5 shows a bindersystem based on starch. Typically the liquor concentration is 15-40%(i.e. solid matter in liquor)

Test no. 1 2 3 4 5 SBR-dispersion 90 40 urea resin 10 10 acrylatedispersion 90 40 starch 60 60 100 Set application (% weight [%] 20 20 2020 20 of raw non-woven) Maximum [daN/5 cm] 56 59 57 51 46 longitudinaltensile force Maximum longitudinal [daN/5 cm] 25 19 27 n.t. 31 tensileforce, hot Maximum cross [daN/5 cm] 47 48 45 36 36 tensile forceLongitudinal TDS [%] 1.8 1.9 1.3 1.6 0.8 Cross TDS [%] −1.6 −1.8 −1.4−1.7 −1.3 VW-Test [mg/kg FA] ~400 ~400 ~30 ~30 <10 Water suction [mm] 8072 72 59 66

1. A textile fabric comprising: textile fibers; and a binder to solidifythe textile fibers into the textile fabric, wherein the binder is formedfrom a binder system comprising an aqueous dispersion of: starch; andemulsion polymers, wherein the textile fabric has a heat dimensionalstability of at most 1.6% in a longitudinal direction and at most 1.7%in a cross direction.
 2. The textile fabric of claim 1, wherein thetextile fibers comprise polyester fibers.
 3. The textile fabric of claim1, wherein the textile fibers comprise spunbonded fibers.
 4. The textilefabric of claim 1, wherein the textile fibers comprise one or more typeof reinforcing fibers selected from the group consisting of aramidfibers, carbon fibers, glass fibers, mineral fibers, high-strengthpolyester fibers, high-strength polyamide fibers, and metal fibers. 5.The textile fabric of claim 1, wherein the starch comprises at least onevegetable starch selected from the group consisting of potatoes, manioc,arrowroot, batata, wheat, maize, rye, rice, barley, millet, oat,sorghum, chestnuts, acorns, beans, peas, and bananas.
 6. The textilefabric of claim 1, wherein the starch comprises a mixture of amylose andamylopectin, and has a molecular weight M_(w) between 5×10⁴ and 1×10⁷.7. The textile fabric of claim 1, wherein the emulsion polymers compriseone or more vinyl aromatic polymers.
 8. The textile fabric of claim 7,wherein the one or more vinyl aromatic polymers comprise styrenepolymers.
 9. The textile fabric of claim 1, wherein the binder systemfurther comprises one or more emulgators.
 10. The textile fabric ofclaim 9, wherein the emulgators are selected from the group consistingof polyalkylene glycol, sulfonated parafinic hydrocarbons, alkylsulphates, and alkaline metallic salts of fatty acids.
 11. The textilefabric of claim 1, wherein the binder system further comprises one ormore additives selected from the group consisting of a preservative, astabilizer, an antioxidant, an antifoaming agent, a waterproofing agent,a UV stabilizer, a filler, and a pigment.
 12. The textile fabric ofclaim 1, wherein the textile fabric has a weight per unit area of 20g/m² to 500 g/m².
 13. An article comprising: a fiber-containing textilefabric; and a binder to solidify the textile fabric, wherein the binderis formed from a binder system comprising an aqueous dispersion of:starch; and emulsion polymers, wherein the article has a heatdimensional stability of at most 1.6% in a longitudinal direction and atmost 1.7% in a cross direction.
 14. The article of claim 13, wherein thearticle is selected from the group consisting of a sarking membrane, aroofing membrane, and a sealing membrane.
 15. The article of claim 14,wherein the roofing membrane comprises a bituminized roofing membrane.16. The article of claim 14, wherein the article further comprises agranular material on at least one surface of the article.
 17. A methodof making an article, the method comprising: forming a plurality offibers into a textile fabric; applying a binder system to the textilefabric, wherein the binder system comprises an aqueous dispersion of:starch; and emulsion polymers, and solidifying the binder system into abinder that is incorporated into the textile fabric, wherein the articlehas a heat dimensional stability of at most 1.6% in a longitudinaldirection and at most 1.7% in a cross direction.
 18. The method of claim17, wherein the textile fabric comprises a spunbond textile fabric. 19.The method of claim 17, wherein the solidifying of the binder systemcomprises drying the binder system.
 20. The method of claim 17, whereinthe article is selected from the group consisting of a sarking membrane,a roofing membrane, and a sealing membrane.